Novel filament stock box

ABSTRACT

This invention relates to new and useful filament holding containers. More specifically, it is concerned with filament stock boxes which accept cut-to-length parallel synthetic filament in such a manner that picking devices can engage the filament at one end (longitudinal to the filament&#39;&#39;s length) and remove at least two prearranged filament tufts prior to insertion of said tufts into a brush construction.

United States Patent [72] Inventor John C. Lewis, Jr. [56] ReferencesCited M'ddlebul'y, UNITED STATES PATENTS [21] Appl. No. 778,741 [22]Filed Nov 25 1968 311,985 2/1885 Hellwig BOO/7X [45] Patented Feb 161971 1,321,394 11/1919 Roseman 300/7 [73] Assignee Tucel Industries,Inc. Primary ExaminerGranville Y. Custer, Jr.

Middlehury, Vt. Attorney-John C. Lewis, Jr.

ABSTRACT: This invention relates to new and useful filament [54] NOVELFILAMINTFS T0CK BOX holding containers. More specifically, it isconcerned with fila- 3 Claims 8 Drawing ment stock boxes which acceptcut-to-length parallel synthetic [52] U.S. Cl 300/7 filament in such amanner that picking devices can engage the [51] Int. Cl A46d 1/04filament at one end (longitudinal to the fiiaments length) and [50]Field of Search 300/5, 7, remove at least two prearranged filament tuftsprior to inser- 18, 19 tion of said tufts into a brush construction.

PATENT EU FEB] a 197i sum 1 or 3 y iiyt.

The need for improving filament stock boxes can be best illustrated bycomparing and describing conventional filament stock boxes with the newand improved future-type filament stock boxes of this invention. Theconventional staple-set brush picking operation employs a picker whichcan remove only one filament tuft at a time from a stock box or feedmechanism by first entering the stock box approximately at itsmidsection (lateral to the parallel filament) and picking a given amountof filament at the filaments midsection. Such filament stock boxes aredisclosed in US. Pat. Nos. 2,433,191 (Baumgartner) and 3,059,972(Schmidt). The picker then proceeds to transport the predeterminedvolume of parallel filament to a suitable means for doubling thefilament at its midsection, just prior to stapling, thus resulting in atuft having a U-shape wherein both ends of each individual filament arelocated at the working end of the resultant tuft. A staple or anchor ofsome sort is then inserted through the U-shape loop and the tuft forcedinto a predrilled hole in a brush back. Each tuft is formed in thismanner, one after another, until the necessary number of filament tuftshave been picked and stapied. The conventional filament stock box holdsfilament having a length double of that of the finished tuft. Also, theconventional stock box merely holds parallel filament and depends uponthe picking wheel for removing a given amount of filament therefrom. Inno way does the ordinary conventional filament stock box participate informing: (l) tuft trim (2) tuft cross section (3) tuft diameter.Ordinary filament stock boxes can only contribute to the formation ofone tuft at one time.

The filament stock boxes of this invention function on an entirelydifferent principle. Said boxes are capable of dispensing two, three orany number of predetermined filament tufts simultaneously, in order thata brush construction containing all its filament tufts can be fabricatedinstantly. First, the filament employed for forming the tufts is halfthe length required for forming tufts in the conventional manner. in myUS. Pat. No. 3,471,202, issued Oct. 7, 1969. I describe tuft-pickingdevices and tuft-forming units wherein brush construction containingtuft filaments are simultaneously picked and fabricated. The tuftpicking devices described in that pending invention work in conjunctionwith the improved stock boxes of this invention, but the picking devicesare not of concern in this instant invention. The picker or picking unitenters the filament stock box longitudinal to the filaments end andengages the filament from one end; at this instant, the filament tuft isformed and trimmed.

Secondly, in order to effect this operation it is necessary to providemeans within the filament stock box for filament alignment and retentionduring the picking. Thirdly, it is necessary to provide means forretaining the unpicked filaments during tuft removal from the stock boxand fourthly, means must be provided for allowing the reserve supply offilaments contained in the filament stock box to be moved into positionfor subsequent picking. Unlike conventional stock boxes, the new andimproved filament stock box of this invention plays an integral partduring tufted brush construction and formation, namely that ofcooperating with the picking unit.

Objects and advantages of the invention will be set forth in parthereinafter and in part will be obvious herefrom, or may be learned bypractice with the invention, the same being realized and attained bymeans of the combinations compositions and improvements pointed out inthe appended claims.

The invention resides in the novel steps, methods, combinations,compositions and improvements herein shown and described.

The objects of this invention will now be described. While thisinvention is primarily concerned with new and novel filament stock boxesfor dispensing synthetic filament for subsequent formation into tuftedbrushes, it should be realized that the principles of this invention areattained only through the novel combination of retaining cut-to-lengthparallel synthetic filament and dispensing those filaments in situationswherein (1) single filament tufts are formed, (2) multiple filamenttufts are formed, (3) complete tufted brush-type constructions aresimultaneously formed and (4) continuous modular tufted strip-type brushconstructions are formed.

it is therefore an object of this invention to provide new and novel anduseful filament stock boxes for dispensing synthetic filament. Anotherobject of this invention is to provide a filament-dispensing stock boxwherein the length of the synthetic filament employed is approximatelythat of the length of the resultant filament tuft formed. A furtherobject of this invention is to provide a filament-dispensing stock boxwherein the resultant filament tufts so formed from the disposedfilament are simultaneously removed from the stock box in the form oftrimmed tufts.

A still further object of this invention is to provide a filament stockbox having integral means for imparting filament alignment and retentionduring picking. Another object of this invention is to provide afilament stock box of the type set forth in the foregoing object whereindisposed cut-to-length synthetic filaments are picked simultaneously byemploying a picking device which enters the filament stock box from thefront through apertures and engages the filament at one end prior toremoval. Yet still another object of this invention is to provide afilament-dispensing stock box having means for allowing a reserve supplyof filaments to be aligned and positioned into the proper attitude forsubsequent tuft formation.

Another object of this invention is to provide a filament dispensingstock box wherein at least two filament tufts having different tuftdiameters are disposed simultaneously. Yet still another object of thisinvention is to provide a filamentdispensing stock box wherein at leasttwo different filament tufts having different lengths are disposedsimultaneously. Another object of this invention is to provide afilament stock box wherein filament tufts having different colors aredisposed simultaneously.

Further objects of this invention are to provide novel methods for theformation of synthetic filament tufts by employing the new and usefulfeatures of the types set forth in the foregoing objects.

The term synthetic filament as used hereinafter is to apply to thosesynthetic monofilaments which are formed from linear thermoplasticpolymers from the group consisting of polystyrene and polystyrenecop'olymers, polyvinyl chloride and polyvinyl chloride-acetatecopolymers, polyethylene, polypropylene, polyethylene-polypropylenecopolymers, polyamides, polyamides, polyesters and polyurethane. Bothoriented and unoriented monofilaments may be employed. Also, variouscross-sectional shapes may be imparted to the monofilaments, such as forinstance, i.e. circular, lobular, trifoil, X and Y cross sections,triangular, polygonal, star, etc. Mixtures of synthetic monofilamentsmay be employed in cases where the compositions of the monofilaments arecompatible during any fusing operations, i.e. heat sealing. Suchfilaments may have suitable crimp imparted to their length or a portionthereof.

The term picking as used in the specification refers to the formation offilament tufts wherein two or more tufts are formed simultaneously byengaging more than one cut-tolength filament by its end and removingsame from a parallel disposed bundle of filaments. The picking devicesemployed are those types which are disclosed in the aforementionedmentioned US. Pat. No. 3,471,202.

The term recess as used in the specification refers to a recessedsection contained on the inside back wall of the filament stock boxwhich provides for holding the tuft ends in alignment during the pickingoperation. This recess is created by allowing a piston-type section ofthe wall to move (index) during the picking process.

The term aperatures as used in the specification refers to an opening inthe face of the stock box, said opening allowing entrance of the pickerinto the filament contained therein. The apertures correspond indimension and shape to the cross section of the pickers.

IN THE DRAWING FIG. 1 is a perspective view of the filament stock box ofthis invention.

FIG. 2 is a longitudinal section through a complete filament stock box,the section being along the line AA-AA in FIG. 1.

FIGS. 3, 4, 5 and 6 are respectively longitudinal sections through acomplete filament stock box illustrating the functions of the workingparts contained in the stock box.

FIGS. 7 and 8 are cross-sectional views illustrating an optional designfor the recess piston of FIG. 2.

The filament stock box illustrated in FIG. 1 comprises a frame 1 inwhich the filament 6 is retained. The front of the filament stock box isprovided with a movable aperture face 2, said face containing apertures3. The aperture face is supported by rod 5 and is kept in an openattitude at all times, except during picking,.by spring 4.

The filament stock box is further provided with a series of recesspistons which are housed in the element 12.

In order to fully illustrate the embodiments of this instant inventionit is necessary to describe the different stages of operation, namelythe picking operation relating to tuft formation. referring now to FIGS.2, 3, 4, 5 and 6, by reference characters, the numeral 1 indicatesgenerally the frame which supports cut-to-length synthetic filament andthe various mechanisms which make up the stock box. The frame 1 consistsof a four-sided box having a closed bottom and open top. There could beother modifications for the top and bottom, but for the sake ofexplanation, the detail shown in FIG. 1 will be considered. The front ofthe filament stock box contains an aperture face 2 containing apertureapproaches 3, said aperture approaches being designed in such a fashionas to act as a guide means for aligning and allowing the tuft-formingpickers to pass therethrough during the picking operation. The apertureface is attached, but not fixed, to the front face of the filament stockbox. Attached to and integral with the back of the frame is section 12which contains the recess piston 9, its stop 10, and spring 11. Therecess piston is so designed that except for picking, its face is flushwith the back inside face of the stock box, thus allowing for free flowof the synthetic filament.

Referring specifically to FIG. 2, it can be shown that at the start ofthe picking operation, the following takes place: filament 6 iscontained in a parallel relationship in frame 1 with its trim endoriented in the direction of the aperture face 2 while its butt end, orsubsequent heat-sealed end, oriented in the direction of the recesspiston 9. Tuft-forming pickers 8 contained in fixture 7 are lined up indirection B in such a manner as to allow entrance of the pickers 8 intothe aperture approach 3 of the aperture face 2. Aperture face 2 isseparated from frame 1 in order that the filament retention ring 13 cannot come into contact with the filament 6. The recess piston is flushwith the inside back wall of frame 1. By indexing fixture 7 of thetuft-forming device in direction B the front of pickers 8 first come incontact with the aperture approaeh 3 of the aperture face 2, and at thesame instant, cause the aperture face 2 to close whereby the filamentretention rings 13 are inserted into the filament 6. Referring to FIG.3, it is shown that at this instant, the recess piston 9 has not beencaused to move in direction 8 since pickers 8 have not as yet come intocontact with filament 6.

Now referring to FIG. 4, as the fixture 7 of the tuft-forming devicecontinues to move in direction B, the front tapered sections of pickers8 become inserted into filament 6, thereby causing pressure in alongitudinal direct against the recess pistons 9, causing the pistons toretract in direction B, allowing the filament ends to move into therecess left by the recess pistons. By this action, the stops it) arecaused to resist pressure from spring 11.

When the entry of the pickers has been completed as in FIG. 5, thetuft-forming pickers 8 have been filled with the required amount offilament for tuft formation. As the fixture 7 moves in reverse,direction C, the pickers 8 retain the filament tufts and as the pickersmove through the aperture retainin rings 13 revent unpicked filament 6from bein remove from the ilament stock box. At this same lnstan recesspistons 9 are caused to move into a flush position with the inside backwall since springs 11 cause stop 10 to be moved forward. As the pickingdevice 7 clears the aperture face, the aperture face then opens and iscaused to move away a slight distance from the frame 1, as shown in FIG.2. At this same instant, more filament 6 is caused to take the emptyplaces left from the picking operation. Thus this process is repeatedover and over again allowing filament to be picked simultaneously.

Referring to FIGS. 7 and 8, there is shown another form for the recesspiston. In FIG. 7, the recess piston 9 is equipped with a filamentretention ring 14 which allows the filament 6 above and below the ringto remain stationary during part of the picking operation. As the recesspiston 9' retracts during tuft formation, the filament retention ring 14does not in any way interfere with the operation, but serves more orless to confine the filament within the provided recess. This is shownin FIG. 8.

By providing a filament stock box with different distances between thefront apertures and the flush recess piston face, it is possible toallow different lengths of cut-to-length synthetic filament to beaccepted within the same filament stock box, thus resulting insimultaneously picking filament tufts of different lengths. Also, byproviding partitions within the filament stock box, that islongitudinally and parallelly to the filament, it would be possible toform a series of filament tufts of more than one type and/or colorsimultaneously.

It should be understood that by providing apertures having differentconfigurations, circular, square, triangular, etc., different tuft crosssections may be obtained. Likewise, by arranging the apertures withinthe aperture face, it is also possible to pick tuft configurationshaving unlimited geometric arrangements.

From the foregoing it will be apparent to those skilled in the art thatthe instant invention provides a very simple and effective filamentstock box for accomplishing the objects of the invention.

The invention in its broader aspects in not limited to the specificsteps, compositions, combinations and improvements described butdepartures may be made therefrom within the scope of the accompanyingclaims without departing from the principles of the invention andwithout sacrificing its chief advantages.

Iclaim:

l. A filament stock box for dispensing precut brush filamentscomprising:

a. a frame having four sides and a bottom;

b. a housing element attached to said frame on a first side andcontaining a plurality of pistons having faces normally coplanar withthe inside face of said first side; and

c. a movable aperture face resiliently mounted in spaced relation to anopening in a second side of said frame opposite said first side; saidaperture face containing a plurality of apertures in the sameconfiguration as said pistons, and each aperture being chamfered at theouter face of said plate; whereby said aperture face will be movedrearwardly as a picker element presses thereagainst and selectedfilament in the frame will depress said pistons.

2. A filament stock box as in claim 1 wherein the configuration of theapertures is that of the tuft configuration of a brush.

3. A filament stock box as in claim 2, wherein said plate has filamentretention rings on its rearward face concentric with each aperture toseparate the filament when the aperture face is moved rearwardly by apicker element.

1. A filament stock box for dispensing precut brush filamentscomprising: a. a frame having four sides and a bottom; b. a housingelement attached to said frame on a first side and containing aplurality of pistons having faces normally coplanar with the inside faceof said first side; and c. a movable aperture face resiliently mountedin spaced relation to an opening in a second side of said frame oppositesaid first side; said aperture face containing a plurality of aperturesin the same configuration as said pistons, and each aperture beingchamfered at the outer face of said plate; whereby said aperture facewill be moved rearwardly as a picker element presses thereagainst andselected filament in the frame will depress said pistons.
 2. A filamentstock box as in claim 1 wherein the configuration of the apertures isthat of the tuft configuration of a brush.
 3. A filament stock box as inclaim 2, wherein said plate has filament retention rings on its rearwardface concentric with each aperture to separate the filament when theaperture face is moved rearwardly by a picker element.